Toggle switch mechanism



Nov. 7, 1961 J. o. ROESER TOGGLE SWITCH MECHANISM Filed Jan. 12, 1959 I NV EN TOR. Lfirzdiaaer Unite States Patent 3,008,024 TOGGLE SWITCH MECHANISM John O. Roeser, Park Ridge, Ill., assignor to Illinois Tool Works, Chicago, 111., a corporation of Illinois Filed Jan. 12, 1959, Ser. No. 786,114 7 Claims. (Cl. 200--172) This invention is concerned with an electric switch, and more particularly with an operating mechanism of a toggle switch.

Ordinary toggle switch mechanisms have a number of drawbacks. Such switches can be easily teased, with consequent arcing and erosion of the contacts. The mechanisms have a very short life and are frequently unreliable. Furthermore, conventional toggle switches lack the flexibility to be adapted to many different applications. Critical tolerances have generally been necessary.

Accordingly, it is an object of this invention to provide a toggle switch mechanism which overcomes the above enumerated difliculties.

More specifically, it is an object of this invention to provide a toggle switch mechanism made to ordinary production tolerances, most particularly, stamping tolerances.

Other and further objects and advantages of the present invention will be apparent from the following description when taken in connection with the accompanying drawings wherein:

FIG. 1 is a perspective view of a switch constructed accordance with the principles of this invention; FIG. 2 is a longitudinal sectional view through the switch as taken along the line 2--2 in FIG. 1 and showing the parts with the switch in on position;

FIG. 3 is a view similar to FIG. 2 showing the parts with the switch in off position; and

FIG. 4 is an exploded perspective view of certain of the switch operating parts.

Referring now in greater particularity to the drawings, there will be seen a switch designated generally by the numeral and including a substantially U-shaped sheet metal base 12. The base is provided at the bight thereof, illustrated at the top of the base, with a threaded bushing 14 for securing to a panel or the like in the usual manner. The bushing is provided with a partial transverse web 16 and a cross pin 18 pivotally mounting an operating member or handle 20 of the type known in the art as a bat handle. The handle at its lower, relatively small diameter end is provided with an axial bore 22 receiving the shank 24 of a headed pin 26 having a convex lower end or undersurface to the head 28. A coil spring 30 encircles the reduced lower end of the bat handle 20 and is compressed between the head 28 and a cylindrical enlargement 32 adjacent the pivot pin 18.

A suitable switch unit 34 of the low travel type is secured at the bottom of the base 12 between the sidewalls thereof by means such as bolts 36. The switch may be of a multiple type, having a plurality of plungers 38 disposed in parallel relation and aligned axially of the pivot pin 18. The switch is provided with terminal means, and in the illustrative embodiment there are two pairs of switch terminals 40 at each end of the switch, corresponding pairs being connected to switch contacts internally, operated by the respective plungers 38.

An operating member or lever 42 in the form of a flat blade or tongue is disposed within the base 12 above the switch unit 34 and is provided at one end with a pair of upstanding ears 44 by means of which it is pivoted on a pin 46 extending across the case in the direction of the pivot pin 18. The operating lever or tongue 42 is arranged to engage near its mid-section with 'ice all of the plungers 38 substantially on aline transverse of the axis of the lever or tongue. The blade, tongue or lever 42 angles up to the left in the switch off position of FIG. 3, and is substantially horizontal in the switch on position of FIG. 2.

A pivot pin 48 is disposed somewhat above the pivot pin 46, and on the center line of the switch 10 in alignment with the pivot pin 18 and the plungers 38. A rocking lever 50 is provided along the center of its longitudinal edges with depending ears 52 pivoted on the pin '48. The rocking lever 50, like the tongue 42 is a sheet metal stamping, and is somewhat wider than the lever 42, whereby the lever 42 may fit between the ears 52, the limit upper position of the lever 42 being determined by engagement with the pivot pin 48-. The tail of the rocking lever 50 is of reduced width as indicated at 42, for fitting between the cars 44, the limit clockwise position (in the drawings) being determined by engagement of the tail 54 of the lever 50 against the pivot pin 46, as in FIG. 3. At the opposite end, the rocking lever 50 is provided with a depending flange 56 which is engageable with the corresponding end of the lever 42. In the limit position, illustrated in FIG. 3, there is a slight clearance space 58 between the flange 56 and the end of the lever 42.

When the switch is in the OE position of FIG. 3, the spring 30 holds the pin head 28 against the rocking lever 50 to the right of the pivot 48, thereby holding the tail 54 down against the pin 46. The internal spring returns of the plungers 38 hold the plungers up against the lever 42, and hence hold the lever up against the pivot pin 48. As noted, the parts are so dimensioned that there is a slight gap between the flange 56 and the end of the lever 42. Thus, the length of the flange and of the other parts can vary somewhat in accordance with ordinary sheet metal stamping tolerances without affecting the parts as to the positions just described.

When the bat handle is pivoted in a clockwise direction (as viewed in the drawings) the head 28 of the pin 26 moves uphill along the rocking lever 50, compressing spring 30, until the head 28 passes a dead center position of the pivots 18 and 48. The rocking lever 50 then immediately starts to pivot in a counterclockwise direction, bringing the flange 56 into engagement with the end of the lever 42, and pivoting the lever 42 in a counterclockwise direction, all with a snap action, whereby to depress the plungers 38 with a snap action. The parts thus immediately move to the switch on position of FIG. 2. Switching in the opposite direction is precisely the reverse of the switching just described.

One advantage of the mechanism is that it makes it possible to obtain simultaneous action of the several switches within the unit 34. Thus, when the upward spring force of the first switch button to move is overcome by the lever 42, there is an immediate diminution of force upward on this lever, and the lever is moved even more rapidly by the spring 30, acting through the pin 26 and the rocking lever 50, whereby substantially instantaneously to depress the other plunger or plungers 38. Ideally, of course, the switches of the unit 34, including the plungers 38 thereof, would be identical. However, production tolerances are such that precise identity is not readily obtainable, and hence the action just described is most advantageous.

It will now be apparent that the spacing 58 between the flange 56 and the lever 42 is of considerable importance in allowing the use of ordinary sheet metal stamping standards. In practice, this gap is quite small, having been exaggerated somewhat in the drawings. In extreme cases, it may be substantially non-existent, whereas in extreme cases in the other direction it will still not be unduly large. The effective size of the gap is reduced relative to the plungers 38 by the lever action of the lever 42.

The specific example of the invention as heretofore shown and described is for illustrative purposes only. Various changes in structure will no doubt occur to those skilled in the art, and will be understood as forming a part of the invention insofar as they fall within the spirit and scope of the appended claims.

The invention is claimed as follows:

1. A toggle switch mechanism comprising a U-shaped sheet material base having a pair of legs and a bight, a switch mounted between said legs of said base adjacent the ends thereof opposite said bight, said switch having an operating member projecting toward said bight, a lever pivoted between said legs on a pivot adjacent to one end of the lever and located to one side of said operating member, said lever being engaged near the longitudinal center thereof by said operating member, a rocking lever pivoted between said legs on the opposite side of said first mentioned lever relative to said switch and having a flange on one end of the rocking lever directed toward the first mentioned lever and engageable with the end thereof opposite from the pivot of the first mentioned lever, and a handle projecting through said bight and pivoted intermediate its ends on said base, said handle having a manually engageable end disposed outside of said base and having a spring loaded end within said base engaging said rocking lever and positioned to move on either side of a dead center position relative to the pivot of said handle and said rocking lever, the spring loaded end of said handle when on one side of said dead center position pivoting said rocking lever and urging the fiange thereon against the coacting end of the first mentioned lever to urge the first mentioned lever against the switch operating member, and said spring loaded end when on the other side of said dead center position oppositely pivoting said rocking lever to allow re verse pivoting of said first mentioned member and return of said operating lever.

2. A toggle switch mechanism as set forth in claim 1 wherein the spring loaded end'of said handle when on said other side of said dead center position urges the end of said rocking lever opposite the flange against the pivot of the first mentioned lever as a limit stop and the first mentioned lever engages the pivot of the rocking lever as a limit stop, said flange being spaced from said first mentioned lever with both levers engaging the respective limit stops.

3. A toggle switch comprising, in combination, support means, a bat lever swingably mounted on said support means by means of a pivot medially located with reference to the bat lever, a generally straight rock lever pivotally supported on said support means by means of a pivot located along the longitudinal midportion of said rock lever and disposed at the side thereof opposite from said bat lever pivot, a generally straight operating lever approximately coextensive in length with said rock lever and swingably mounted on said support means by means of a pivot at one end of said operating lever located between the operating lever and the rock lever in position to be abuttingly engaged by a corresponding one end of said rock lever, all of said lever pivots being substantially parallel to each other, the other end of said rock lever being turned toward said operating lever to form an abutment for abutting engaging the adjacent end of the operating lever upon swinging movement of the rock lever in a direction which carries said one end thereof away from said operating lever pivot, a switch unit mounted on said support means at the side of said operating lever opposite from said rock lever and including an operating plunger continuously urged into engagement with-a medial longitudinal portion of said operating lever to urge the latter toward said rock lever, said bat lever having a spring loaded end engaging the adjacent side of said rock lever to effect swinging movement of the rock lever between first and second switch operating positions as an incident to swinging of the bat lever to carry said spring loaded end to alternate sides of a dead center position with reference to the pivots of said bat lever and said rock lever, said rock lever engaging said operating lever pivot when said rock lever is in said first position thereof, said abutment on said rock lever being dimensioned to allow said plunger to swingably engage said operating lever with said rock lever pivot when said rock lever is in said first position thereof, and said rock lever upon being swung by sm'd bat lever to said second position acting through said operating lever to depress said plunger to effect operation of said switch unit.

4. A toggle switch comprising, in combination support means, a bat lever swingably mounted on said support means by a pivot medially located with reference to said bat lever, a switch unit mounted on said support means and including a switch operating plunger extending and biased toward said bat lever pivot in spaced relation thereto, a generally straight rock lever disposed between said bat lever and said plunger, a pivot on said support means lo cated on the plunger side of said rock lever in a positioning along the lever spaced approximately equal distances from opposite ends thereof and supporting said rock lever for swinging movement between a switch open position and a switch closed position, spring biased pressure means on one end of said bat lever continuously engaging said rock lever to swing the latter between said switch positions thereof as an incident to operation of the bat lever to move said pressure means to opposite sides of a dead center position with respect to said bat lever and rock lever pivots, an operating lever approximately coextensive in length with said rock lever and disposed between the latter and said plunger to be continuously engaged by the plunger, a support pivot for said operating lever located at one end of the operating lever and supported on said support means between said operating lever and said rock lever to engage and serve as a stop for the latter upon movement thereof to one of said switch positions thereof, said operating lever and said rock lever being dimensioned and shaped to allow said plunger to move said operating lever into engagement with said rock lever pivot when said rock lever is in said one switch position thereof, one of said rock and operating levers having an end thereof opposite from said operating lever pivot shaped to engage the adjacent end of the other of said rock and operating levers to effect swinging movement of said operating lever away from said rock lever pivot against said plunger as an incident to movement of said rock lever to the other of said switch positions thereof.

5. A toggle switch comprising, in combination, support means, a bat lever swingably mounted on said support means by a medial pivot, a switch unit mounted on said support means and inculding a switch operating plunger extending and biased toward said bat lever pivot in spaced relation thereto, an elongated rock lever disposed between said bat lever and said plunger, a pivot on said support means located on the plunger side of said rock lever and supporting said rock lever adjacent the longitudinal center thereof for swinging movement between a switch open position and a switch closed position, spring biased pressure means on said bat lever continuously engaging said rock lever to swing the latter between said switch positions thereof as an incident to operation of the bat lever to move said pressure means to opposite sides of a dead center position with respect to said bat lever and rock lever pivots, an elongated opearting lever disposed between said rock lever and said plunger to be continuously engaged by the plunger adjacent the longitudinal center of the operating lever, a support pivot for said operating lever located at one end of the operating lever and supported on said support means between said operating lever and said rock lever to engage and serve as a stop for the latter upon movement thereof to one of said switch positions thereof, said operating lever and said rock lever being dimensioned and shaped to allow said plunger to move said operating lever into engagement with said rock lever pivot when said rock lever is in said one switch position thereof, said rock and operating levers being shaped to engage one end of said rock lever with the endof said operating lever opposite from said operating lever pivot to effect swinging movement of said operating lever away from said rock lever pivot against said plunger as an incident to movement of said rock lever to the other of said switch positions thereof, and said rock and operating levers being shaped and dimensioned to provide clearance space between said one end of said rock lever and the coacting end of said operating lever upon movement of said rock lever into engagement with the operating lever pivot and engagement of said operating lever with said rock lever pivot.

6. A toggle switch comprising, in combination, support means, a bat lever swingably mounted on said support means by a pivot disposed between opposite ends of the bat lever, a switch unit mounted on said support means and including a switch operating plunger extending and biased toward said bat lever pivot in space relation thereto, an elongated rock lever disposed between said bat lever and said plunger, a pivot on said support means supporting said rock lever adjacent the longitudinal center thereof for swinging movement between a switch open position and a switch closed position, spring biased pressure means on one end of said bat lever continuously engaging said rock lever to swing the latter between said switch positions thereof as an incident to operation of the bat lever to move said pressure means to opposite sides of a dead center position with respect to said bat lever and rock lever pivots, an operating lever approximately coextensive in length with said rock lever and disposed between the latter and said plunger to be continuously engaged by the plunger, 21 support pivot for said operating lever located at one end of the operating lever and supported on said support means, one of said rock and operating levers having an end thereof opposite from said operating lever pivot shaped to engage the adjacent end of the other of said rock and operating levers to efiect swinging movement of said operating lever against said plunger as an incident to movement of said rock lever to one of said switch positions thereof.

7. A toggle switch comprising, in combination, support means, a swingable operating lever, means pivotally supporting said operating lever at one end thereof on said support means, a switch unit supported on said support means and including a biased operating member engaging said operating lever adjacent the longitudinal center thereof, a rock lever substantially equal in length to said op erating lever, said rock lever being rockably supported on said support means by means of a pivot located along the length of said rock lever adjacent the longitudinal center thereof, a bat lever supported by a medial pivot on said support means and including pressure means engaging said rock lever to swing the latter between two switch operating positions thereof as an incident to movement of said pressure means to opposite sides of a dead center position between the bat lever pivot and said rock lever pivot, and said rock lever and said operating lever being shaped to effect between the end of said operating lever opposite from the pivotal support thereof and one extreme end of said rock lever a coacting relation which effects swinging movement of said operating lever against said plunger as an incident to movement of said rock lever to one of said switch positions thereof.

References Cited in the file of this patent Patent No. 3 OO8,O24

. corrected below.

UNITED STATES PATENT. OFFICE D g CERTIFICATE-0F CORRECTION M wovem k 1961 John O. Roeser p I It is hereby certified that error appears in the above numbered patent requiring correction and that the said Letters Patent should read as Column 3, line 38, for "member" read lever line 39, for "lever" read member 'Signed and sealed this 8th day of May 1962.

(SEAL) Attest:

DAVID L. LADD ERNEST W. swmEfi Attesting Officer Commissioner of Patents 

